We had an ADP C60A210L186 AC heat exchanger instal...
We had an ADP C60A210L186 AC heat exchanger installed as part of an AC retrofit by Sears using a local contractor just under two years ago. Last week during a heat wave, it failed completely the fan was running and the exterior condenser was running, but there was no air flow and no cooling. After investigating, we discovered a gaping hole in between the ADP unit and the heater; the installer had patched it with tape/mastic, but the tape had blown out and air was rushing out of a 24 by 2 gap, bypassing the heat exchanger completely. After I patched it, there was still no air flow, and we realized that the heat exchanger coils must have frozen solid. After they thawed, the AC worked, but at reduced capacity cooling was at a much reduced level and air flow, while present, was way below normal levels. Since Sears has been utterly useless in the warranty department (will never make that mistake again), I contacted the original installer, but they refused to touch it since they claimed that Sears had apparently never paid them for the work. So I opened the heat exchanger myself and found the root cause of all of the issues. The interior surface of the heat exchanger enclosure has a blanket of mylar(?)/insulation that extends along the back wall and along the left and right side walls. That blanket was glued in with a spectacularly ineffective adhesive that was, at the time I discovered it, doing no adhering to the walls of the enclosure at all. This allowed the blanket to come loose from the left and right side walls, at which point the left and right ends of the blanket simply fell onto the heat exchanger and blocked almost all air flow therethrough. I believe that this then caused the plenum pressure to rise, which caused the tape patch to blow out, and once the air was no longer constrained to flow through the plenums, it simply bypassed the heat exchanger entirely, leading the heat exchanger to freeze. I fixed the blanket in place using some fender washers and rivets, and it is now extremely secure. Overall, I was very unimpressed with the design of the insulation system I m sure glue is inexpensive, but I feel that glue alone should never have been relied upon to keep the blanket in place when failure of the glue could lead to the unit being completely crippled.